2005 Lotus Elise Headlight Cover Removal Issue - LotusTalk - The Lotus Cars Community
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post #1 of 12 (permalink) Old 12-04-2017, 11:34 PM Thread Starter
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2005 Lotus Elise Headlight Cover Removal Issue

Hi All,

My passenger side low beam went out today and when trying to take off the housing cover I ran into an issue. I followed this https://www.lotustalk.com/forums/f286...-exige-112974/ however in step 2, it doesn't appear I have 3 allen head bolts. Instead there are two rubber covers and one is a empty slot (appears screw is missing). I peeled off one rubber cover and there was a screw hole but no screw. I peeled off the other rubber cover and there is a screw but the head is flat with no ability to actually turn the screw.

Any idea what I should do at this point?

Thanks in advance!


https://photos.app.goo.gl/JJxHj8Hd9v2k8Exn2
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post #2 of 12 (permalink) Old 12-05-2017, 01:33 AM
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Those 3 mounting points on the headlight cover have c-clips that the 3 allen head bolts (which are obviously gone in your case) screw into, and are known to break. Just a guess, but possible previous owner broke all of them and attached cover with silicone or something? Do the covers move at all against the front clam to suggest they were glued in? Also possible bungee cord fix is at play here?
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"In general, the Elise will be kept in best operating condition by regular use."
Page 152 Lotus Elise owner's manual
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post #3 of 12 (permalink) Old 12-05-2017, 11:19 AM Thread Starter
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Thanks for the reply Blaising!

So after looking at it this morning I just need to get the bolt (that can't be turned with a tool) out. It has a flat round head, do you think I should take a dremel to the head and use a flat head screw driver to get it out? If I get the screw out then there shouldn't be anything else holding the cover on right?
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post #4 of 12 (permalink) Old 12-05-2017, 12:05 PM
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That sounds like a solid plan to me. There shouldn't be anything else holding the lens on. You are already in the WTF end of the swimming pool on this one, so just be gentle when removing it.
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post #5 of 12 (permalink) Old 12-05-2017, 12:39 PM
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The headlight buckets are a problem. The first time I removed mine, I discovered the tabs were broken and that a previous owner had used some type of hardening putty to secure the buckets to the clam. I went the route of riveting plumber's strap the the broken posts and then attaching the Speed Nuts to that. It was a learning process.
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post #6 of 12 (permalink) Old 12-05-2017, 01:37 PM
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Someone sells a headlight bucket hardware refresh kit, I was just looking for it but couldn't locate it. It's probably a good thing to have.

2006 Exige
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post #7 of 12 (permalink) Old 12-05-2017, 03:13 PM
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I repaired several of my mounting posts with this stuff. You can mold ot with your fingers, drill it, sand it. Also used this stuff to fix the broken tab on my turn signal housing.
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"In general, the Elise will be kept in best operating condition by regular use."
Page 152 Lotus Elise owner's manual
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post #8 of 12 (permalink) Old 12-05-2017, 03:43 PM
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GRP makes a tab repair kit for the light buckets for 2006 and earlier.

Here is the link:
https://gregsraceparts.squarespace.c...t?rq=headlight
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06 Lotus Elise: Ardent Red, Sport+Touring, ShiftR111, S111 TransCables, LETSLA, Driving lights
02 Honda S2000: Spa yellow, Berk Hi-flow Cat, Alpine head unit, Focal speakers
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post #9 of 12 (permalink) Old 12-05-2017, 04:53 PM
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Quote:
Originally Posted by BigHair View Post
GRP makes a tab repair kit for the light buckets for 2006 and earlier.

Here is the link:
https://gregsraceparts.squarespace.c...t?rq=headlight
That's where I saw it, thanks! Looked on Greg's site but couldn't find it.
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post #10 of 12 (permalink) Old 12-05-2017, 10:02 PM Thread Starter
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Thank you all for the help and responses!

I took the dremel to the screw and it worked out great. Luckily, the headlight cover's tabs are all intact and now I just need to make a run to the hardware store tomorrow to pick up some proper screws and washers.

Here's some pictures if anyone is interested: https://photos.app.goo.gl/Q8LVLIg1lsf4fOCI3
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post #11 of 12 (permalink) Old 12-06-2017, 03:37 AM
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Wow, did you get lucky. Maybe time to buy a couple lotto tickets?!?!

2005 Chrome Orange Elise, BWR supercharger, TR Motorsport F1 rims and R888s, Nitron NTR40 Single Adjustables with Eibach springs,Sector 111 308BBL brakes, BWR Silent Touch exhaust, CF side scoops, front splitter, and engine cover.
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post #12 of 12 (permalink) Old 12-06-2017, 07:28 AM
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That headlight hardware refresh kit is exactly what I need! Didn't even know this existed...
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